U.S. patent application number 13/237542 was filed with the patent office on 2012-01-12 for multi-output valve and burner useful to promote non-stationary flame.
Invention is credited to Bryan R. Bielec, Mark Allen Kailburn, William Thoru Kobayashi, James Patrick Meagher, Friedrich Eduard Purkert.
Application Number | 20120009533 13/237542 |
Document ID | / |
Family ID | 39685049 |
Filed Date | 2012-01-12 |
United States Patent
Application |
20120009533 |
Kind Code |
A1 |
Meagher; James Patrick ; et
al. |
January 12, 2012 |
MULTI-OUTPUT VALVE AND BURNER USEFUL TO PROMOTE NON-STATIONARY
FLAME
Abstract
A valve useful in distributing gas received in one inlet to
several outlets in a sequence, and burner apparatus including this
valve for feeding material in sequence to outlets of a burner
thereby forming a non-stationary flame at the burner.
Inventors: |
Meagher; James Patrick;
(Buffalo, NY) ; Kailburn; Mark Allen; (Tonawanda,
NY) ; Kobayashi; William Thoru; (East Amherst,
NY) ; Bielec; Bryan R.; (Hamburg, NY) ;
Purkert; Friedrich Eduard; (Buffalo, NY) |
Family ID: |
39685049 |
Appl. No.: |
13/237542 |
Filed: |
September 20, 2011 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
12028416 |
Feb 8, 2008 |
8033295 |
|
|
13237542 |
|
|
|
|
60900147 |
Feb 8, 2007 |
|
|
|
Current U.S.
Class: |
431/12 ;
431/18 |
Current CPC
Class: |
F23N 1/007 20130101;
F23D 11/108 20130101; F23D 1/00 20130101; F23N 2235/24 20200101;
F23K 2203/105 20130101; F23K 5/147 20130101; F16K 11/076 20130101;
F16K 11/0856 20130101; Y10T 137/86863 20150401; F23D 14/22
20130101; Y10T 137/86501 20150401 |
Class at
Publication: |
431/12 ;
431/18 |
International
Class: |
F23N 1/00 20060101
F23N001/00 |
Claims
1. Burner apparatus comprising (A) a central feed port having an
axis; (B) first supply apparatus for injecting a first stream
comprising material selected from the group consisting of fuel,
oxidant, and mixtures thereof, through the central feed port along
the axis of the central feed port; (C) three or more outer ports,
each having an axis which converges or diverges with respect to the
axis of the central feed port; and (D) three or more unbranched
supply lines, equal in number to the number of outer ports, wherein
one end of each of said supply lines is connected to a different
one of said supply ports and the other end of each of said supply
lines is connected to a controllable supply apparatus for
sequentially injecting material selected from the group consisting
of fuel, oxidant, inert material, and mixtures thereof, into and
through different ones of said supply lines whereby said material
is sequentially ejected from different ones of said outer ports as
a sequence of second streams having a momentum sufficient to
deflect the first stream from the axis of said central feed port,
wherein said controllable supply apparatus comprises (E) a valve
that comprises a valve body having a valve chamber therein having
opposed first and second ends and a side surface extending between
said ends, the valve chamber including a first region that extends
from the first end of the valve chamber and that has an axis, a
valve distributor within the valve chamber and rotatable therein in
said first region about said axis, the valve distributor having
opposed first and second ends and a side surface between said ends,
that is positioned with its first end facing the first end of the
valve chamber and with its side surface facing at least a portion
of the first region of the valve chamber, said valve chamber
including an open space that is bounded by the second end of said
valve distributor, the second end of the valve chamber, and the
side surface of said valve chamber, the valve body having an inlet
extending therethrough from the outer surface of said valve body to
said open space, the valve distributor containing a channel
extending inwardly from the side surface of the valve distributor
and extending from the second end of the valve distributor at least
a portion of the distance toward the first end of the valve
distributor, to receive gas from said open space, the valve body
having two or more outlets extending therethrough from the outer
surface of said valve body to points in the first region of the
valve chamber that face the side surface of the valve distributor
or at least a portion of said channel, wherein the outlets are
dimensioned and located with respect to each other so that at any
rotational orientation of the valve distributor the channel is open
to one outlet or to more than one outlet, and so that when the
channel is open to more than one outlet at the same time the sum of
the interfacial areas at said outlets stays within 90% above or
below the maximum interfacial area when the channel is open to only
one outlet, and wherein the space between the side surface of the
valve distributor and the side surface of the valve chamber, and
the space between the first end of the valve distributor and the
first end of the valve chamber, are small enough that when gas is
fed into said inlet the amount that flows through said spaces to an
outlet that is not open to the channel is less than the amount of
gas that flows through the channel to the outlet or outlets to
which at least a portion of the channel is open, and (F) a
controller for turning said valve distributor about its axis so
that said channel is sequentially open to different ones of said
outlets so as to sequentially provide said material from said open
space through said channel to said outlets.
2. Apparatus according to claim 1 wherein the central feed port has
one opening.
3. Apparatus according to claim 1 wherein the central feed port has
2 to 8 openings.
4. Apparatus according to claim 1 wherein the first stream
comprises fuel and the second stream comprises oxidant.
5. Apparatus according to claim 1 wherein the first stream
comprises oxidant and the second stream comprises fuel.
6. Apparatus according to claim 1 wherein the first stream
comprises a mixture of fuel and oxidant.
7. Apparatus according to claim 1 wherein the second stream
comprises a mixture of fuel and oxidant.
8. Apparatus according to claim 1 wherein the first stream
comprises fuel and the second stream does not contain material that
participates in the combustion of said fuel and oxidant.
9. Apparatus according to claim 1 wherein said valve further
comprises within said valve distributor a passageway one end of
which opens to said channel and another end of which opens to a
point located on the side surface of the valve distributor that
cannot be open to an outlet that is at the same time open to at
least a portion of the channel.
10. Apparatus according to claim 9 wherein said valve further
comprises a flow control that can be adjusted to control the amount
of gas that can flow through said passageway.
11. Apparatus according to claim 1 wherein the first region of said
valve chamber and the valve body rotatable therein are
cylindrical.
12. Apparatus according to claim 1 wherein the first region of said
valve chamber and the valve body rotatable therein are conical.
13. Apparatus according to claim 1 wherein said channel extends
from the second end of said valve distributor toward the first end
of the valve distributor in a direction parallel to said axis.
14. Apparatus according to claim 1 wherein the outlets are
dimensioned and located with respect to each other so that when the
channel is open to more than one outlet at the same time the sum of
the interfacial areas at said outlets stays within 50% above or
below the maximum interfacial area when the channel is open to only
one outlet.
15. Burner apparatus comprising (A) a central feed port having an
axis; (B) three or more outer ports, each having an axis which
converges or diverges with respect to the axis of the central feed
port; (C) one or more auxiliary feed ports situated closer to the
central feed port than any of said outer ports are; (D) first
supply apparatus for injecting a first stream comprising material
selected from the group consisting of fuel, oxidant, and mixtures
thereof, through the central feed port along the axis of said
central feed port; (E) auxiliary stream supply apparatus for
injecting an auxiliary stream comprising material selected from the
group consisting of fuel, oxidant, and mixtures thereof, through
said auxiliary feed ports non-sequentially; provided that at least
one of said first stream and said auxiliary stream comprises fuel
and at least one of said first stream and said auxiliary stream
comprises oxidant, and (F) three or more unbranched supply lines,
equal in number to the number of outer ports, wherein one end of
each of said supply lines is connected to a different one of said
supply ports and the other end of each of said supply lines is
connected to a controllable supply apparatus for sequentially
injecting material selected from the group consisting of fuel,
oxidant, inert material, and mixtures thereof, into and through
different ones of said supply lines whereby said material is
sequentially ejected from different ones of said outer ports as a
sequence of second streams having a momentum sufficient to deflect
the first stream from the axis of said central feed port, wherein
said controllable supply apparatus comprises (G) a valve that
comprises a valve body having a valve chamber therein having
opposed first and second ends and a side surface extending between
said ends, the valve chamber including a first region that extends
from the first end of the valve chamber and that has an axis, a
valve distributor within the valve chamber and rotatable therein in
said first region about said axis, the valve distributor having
opposed first and second ends and a side surface between said ends,
that is positioned with its first end facing the first end of the
valve chamber and with its side surface facing at least a portion
of the first region of the valve chamber, said valve chamber
including an open space that is bounded by the second end of said
valve distributor, the second end of the valve chamber, and the
side surface of said valve chamber, the valve body having an inlet
extending therethrough from the outer surface of said valve body to
said open space, the valve distributor containing a channel
extending inwardly from the side surface of the valve distributor
and extending from the second end of the valve distributor at least
a portion of the distance toward the first end of the valve
distributor, to receive gas from said open space, the valve body
having two or more outlets extending therethrough from the outer
surface of said valve body to points in the first region of the
valve chamber that face the side surface of the valve distributor
or at least a portion of said channel, wherein the outlets are
dimensioned and located with respect to each other so that at any
rotational orientation of the valve distributor the channel is open
to one outlet or to more than one outlet, and so that when the
channel is open to more than one outlet at the same time the sum of
the interfacial areas at said outlets stays within 90% above or
below the maximum interfacial area when the channel is open to only
one outlet, and wherein the space between the side surface of the
valve distributor and the side surface of the valve chamber, and
the space between the first end of the valve distributor and the
first end of the valve chamber, are small enough that when gas is
fed into said inlet the amount that flows through said spaces to an
outlet that is not open to the channel is less than the amount of
gas that flows through the channel to the outlet or outlets to
which at least a portion of the channel is open, and (H) a
controller for turning said valve distributor about its axis so
that said channel is sequentially open to different ones of said
outlets so as to sequentially provide said material from said open
space through said channel to said outlets.
16. Apparatus according to claim 15 wherein said one or more
auxiliary feed ports is an annular orifice around the central feed
port.
17. Apparatus according to claim 15 wherein the streams injected by
said controllable supply apparatus do not contain material that
participates in the combustion of said fuel and oxidant.
18. Apparatus according to claim 15 wherein said first stream
comprises fuel, said second stream comprises oxidant, and the
streams injected by said controllable supply apparatus comprise
oxidant.
19. Apparatus according to claim 15 wherein said first stream
comprises fuel, said second stream comprises oxidant, and the
streams injected by said controllable supply apparatus do not
contain material that participates in the combustion of said fuel
and oxidant.
20. Apparatus according to claim 15 wherein said valve further
comprises within said valve distributor a passageway one end of
which opens to said channel and another end of which opens to a
point located on the side surface of the valve distributor that
cannot be open to an outlet that is at the same time open to at
least a portion of the channel.
21. Apparatus according to claim 20 wherein said valve further
comprises a flow control that can be adjusted to control the amount
of gas that can flow through said passageway.
22. Apparatus according to claim 15 wherein the first region of
said valve chamber and the valve body rotatable therein are
cylindrical.
23. Apparatus according to claim 15 wherein the first region of
said valve chamber and the valve body rotatable therein are
conical.
24. Apparatus according to claim 15 wherein said channel extends
from the second end of said valve distributor toward the first end
of the valve distributor in a direction parallel to said axis.
25. Apparatus according to claim 15 wherein the outlets are
dimensioned and located with respect to each other so that when the
channel is open to more than one outlet at the same time the sum of
the interfacial areas at said outlets stays within 50% above or
below the maximum interfacial area when the channel is open to only
one outlet.
26. A combustion method comprising (A) injecting a first stream
comprising material selected from the group consisting of fuel,
oxidant, and mixtures thereof, through a central feed port that has
an axis, along the axis of said central feed port; (B) providing
three or more outer ports each having an axis which converges or
diverges with respect to the axis of the central feed port; (C)
providing three or more unbranched supply lines, equal in number to
the number of outer ports, wherein one end of each of said supply
lines is connected to a different one of said supply ports and the
other end of each of said supply lines is connected to a
controllable supply apparatus for sequentially injecting material
selected from the group consisting of fuel, oxidant, inert
material, and mixtures thereof, into and through different ones of
said supply lines, (D) sequentially injecting said material into
different ones of said supply lines and thereby sequentially
ejecting said material through different ones of one or more of
said outer ports as a sequence of second streams having sufficient
momentum to deflect said injected first stream from the axis of
said central feed port and to form a mixture with the deflected
first stream, and (E) combusting the mixture of first and second
streams, wherein said controllable supply apparatus comprises (F) a
valve that comprises a valve body having a valve chamber therein
having opposed first and second ends and a side surface extending
between said ends, the valve chamber including a first region that
extends from the first end of the valve chamber and that has an
axis, a valve distributor within the valve chamber and rotatable
therein in said first region about said axis, the valve distributor
having opposed first and second ends and a side surface between
said ends, that is positioned with its first end facing the first
end of the valve chamber and with its side surface facing at least
a portion of the first region of the valve chamber, said valve
chamber including an open space that is bounded by the second end
of said valve distributor, the second end of the valve chamber, and
the side surface of said valve chamber, the valve body having an
inlet extending therethrough from the outer surface of said valve
body to said open space, the valve distributor containing a channel
extending inwardly from the side surface of the valve distributor
and extending from the second end of the valve distributor at least
a portion of the distance toward the first end of the valve
distributor, to receive gas from said open space, the valve body
having two or more outlets extending therethrough from the outer
surface of said valve body to points in the first region of the
valve chamber that face the side surface of the valve distributor
or at least a portion of said channel, wherein the outlets are
dimensioned and located with respect to each other so that at any
rotational orientation of the valve distributor the channel is open
to one outlet or to more than one outlet, and so that when the
channel is open to more than one outlet at the same time the sum of
the interfacial areas at said outlets stays within 90% above or
below the maximum interfacial area when the channel is open to only
one outlet, and wherein the space between the side surface of the
valve distributor and the side surface of the valve chamber, and
the space between the first end of the valve distributor and the
first end of the valve chamber, are small enough that when gas is
fed into said inlet the amount that flows through said spaces to an
outlet that is not open to the channel is less than the amount of
gas that flows through the channel to the outlet or outlets to
which at least a portion of the channel is open, and (G) a
controller for turning said valve distributor about its axis so
that said channel is sequentially open to different ones of said
outlets so as to sequentially provide said material from said open
space through said channel to said outlets.
27. A combustion method comprising (A) injecting a first stream
comprising material selected from the group consisting of fuel,
oxidant, and mixtures thereof, through a central feed port that has
an axis, along the axis of said central feed port; (B) providing
three or more outer ports each having an axis which converges or
diverges with respect to the axis of the central feed port; (C)
providing one or more auxiliary feed ports situated closer to the
central feed port than any of said outer ports are; (D) injecting
an auxiliary stream comprising material selected from the group
consisting of fuel, oxidant, and mixtures thereof, through said
auxiliary feed ports non-sequentially; provided that at least one
of said first stream and said auxiliary stream comprises fuel and
at least one of said first stream and said auxiliary stream
comprises oxidant, (E) providing three or more unbranched supply
lines, equal in number to the number of outer ports, wherein one
end of each of said supply lines is connected to a different one of
said supply ports and the other end of each of said supply lines is
connected to a controllable supply apparatus for sequentially
injecting material selected from the group consisting of fuel,
oxidant, inert material, and mixtures thereof, into and through
different ones of said supply lines, (F) sequentially injecting
said material into different ones of said supply lines and thereby
sequentially ejecting said material through different ones of one
or more of said outer ports as a sequence of second streams having
sufficient momentum to deflect said injected first stream from the
axis of said central feed port and to form a mixture with the
deflected first stream, and (G) combusting the mixture of first and
second streams, wherein said controllable supply apparatus
comprises (H) a valve that comprises a valve body having a valve
chamber therein having opposed first and second ends and a side
surface extending between said ends, the valve chamber including a
first region that extends from the first end of the valve chamber
and that has an axis, a valve distributor within the valve chamber
and rotatable therein in said first region about said axis, the
valve distributor having opposed first and second ends and a side
surface between said ends, that is positioned with its first end
facing the first end of the valve chamber and with its side surface
facing at least a portion of the first region of the valve chamber,
said valve chamber including an open space that is bounded by the
second end of said valve distributor, the second end of the valve
chamber, and the side surface of said valve chamber, the valve body
having an inlet extending therethrough from the outer surface of
said valve body to said open space, the valve distributor
containing a channel extending inwardly from the side surface of
the valve distributor and extending from the second end of the
valve distributor at least a portion of the distance toward the
first end of the valve distributor, to receive gas from said open
space, the valve body having two or more outlets extending
therethrough from the outer surface of said valve body to points in
the first region of the valve chamber that face the side surface of
the valve distributor or at least a portion of said channel,
wherein the outlets are dimensioned and located with respect to
each other so that at any rotational orientation of the valve
distributor the channel is open to one outlet or to more than one
outlet, and so that when the channel is open to more than one
outlet at the same time the sum of the interfacial areas at said
outlets stays within 90% above or below the maximum interfacial
area when the channel is open to only one outlet, and wherein the
space between the side surface of the valve distributor and the
side surface of the valve chamber, and the space between the first
end of the valve distributor and the first end of the valve
chamber, are small enough that when gas is fed into said inlet the
amount that flows through said spaces to an outlet that is not open
to the channel is less than the amount of gas that flows through
the channel to the outlet or outlets to which at least a portion of
the channel is open, and (I) a controller for turning said valve
distributor about its axis so that said channel is sequentially
open to different ones of said outlets so as to sequentially
provide said material from said open space through said channel to
said outlets.
Description
[0001] This application is a division of, and claims priority from,
U.S. patent application Ser. No. 12/028,416, filed Feb. 8, 2008,
which claims priority from U.S. Provisional Application Ser. No.
60/900,147, filed Feb. 8, 2007, the content of which is hereby
incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to apparatus and methods
useful in carrying out combustion.
BACKGROUND OF THE INVENTION
[0003] Many industrial processes require subjecting material to
elevated temperatures on the order of 1000.degree. F. to
3000.degree. F. Examples of such processes include melting aluminum
and other metals, maintaining molten metal in the molten state,
melting glassmaking materials, and maintaining glass in the molten
state. To generate the required elevated temperature, processes
requiring such elevated temperatures often combust carbonaceous
fuel, in one or more burners each of which produces a flame
situated close enough to the material that the heat of combustion
establishes the desired elevated temperature in the material.
[0004] Typically the one or more burners used for this purpose each
generate a flame that extends outward from the burner in a fixed
position, such as extending from a side wall of a furnace across
and over the top of a portion of the material to be heated. Such
arrangements are not necessarily as efficient as possible, because
the temperatures at various points around the outer surface of the
flame and along the length of the flame are not uniform so that
there is a region of the flame that has the highest temperature and
heat flux to the material. This lack of uniformity means that the
position of the burner relative to the material being heated, and
the conditions under which the burner is operated, must be set so
that the highest temperatures and heat flux generated by the burner
are not so high as to produce unwanted results such as "hot spots"
in the material or the enclosure in which the combustion is being
carried out, excessive oxidation of the material, or damage to the
enclosure. However, doing so often requires accepting temperatures
at other points around the flame that are not as high as could be
tolerated, and thereby requires accepting less than optimum
performance of the burner.
[0005] This lack of efficiency has heretofore been considered
acceptable for a number of reasons including the absence of a
useful method and apparatus that can provide greater uniformity of
temperature. The present invention provides apparatus and methods
of use that overcome this lack of efficiency.
BRIEF SUMMARY OF THE INVENTION
[0006] The present invention provides a method and apparatus that
are useful in permitting combustion to be carried out in a manner
that affords a more uniform temperature of the surface of the
material to be heated, or heated and melted.
[0007] One aspect of the present invention comprises a valve useful
for feeding gas to one or more than one outlets at a total flow
rate that is controlled independently of the number of such
outlets, comprising [0008] a valve bodyhaving a valve chamber
therein having opposed first and second ends and a side surface
extending between said ends, the valve chamber including a first
region that extends from the first end of the valve chamber and
that has an axis, [0009] a valve distributor within the valve
chamber and rotatable therein in said first region about said axis,
the valve distributor having opposed first and second ends and a
side surface between said ends, that is positioned with its first
end facing the first end of the valve chamber and with its side
surface facing at least a portion of the first region of the valve
chamber, [0010] said valve chamber including an open space that is
bounded by the second end of said valve distributor, the second end
of the valve chamber, and the side surface of said valve chamber,
[0011] the valve body having an inlet extending therethrough from
the outer surface of said valve body to said open space, [0012] the
valve distributor containing a channel extending inwardly from the
side surface of the valve distributor and extending from the second
end of the valve distributor axis at least a portion of the
distance toward the first end of the valve distributor, to receive
gas from said open space, [0013] the valve body having two or more
outlets extending therethrough from the outer surface of said valve
body to points in the first region of the valve chamber that face
the side surface of the valve distributor or at least a portion of
said channel, [0014] wherein the outlets are dimensioned and
located with respect to each other so that at any rotational
orientation of the valve distributor the channel is open to one
outlet or to more than one outlet, and so that when the channel is
open to more than one outlet at the same time the sum of the
interfacial areas at said outlets stays within 90%, preferably
within 50%, above or below the maximum interfacial area when the
channel is open to only one outlet, and [0015] wherein the space
between the side surface of the valve distributor and the side
surface of the valve chamber, and the space between the first end
of the valve distributor and the first end of the valve chamber,
are small enough that when gas is fed into said inlet the amount
that flows through said spaces to an outlet that is not open to the
channel is less than the amount of gas that flows through the
channel to the outlet or outlets to which at least a portion of the
channel is open.
[0016] In a preferred embodiment of this valve, the valve
distributor further comprises a first spindle that extends axially
from said first end into the first end of said valve chamber, and a
second spindle that extends axially from said second end into the
second end of said valve chamber without occupying all of said open
space, and wherein said valve body contains bearings on which said
first and second spindles are rotatable about said axis.
[0017] In a further preferred embodiment of this valve, a
passageway is provided within said valve distributor such that one
end of the passageway opens to said channel and another end of the
passageway opens to a point located on the side surface of the
valve distributor that cannot be open to an outlet that is at the
same time open to at least a portion of the channel. This
passageway may further comprise a flow control that can be adjusted
to control the amount of gas that can flow through the
passageway.
[0018] Another aspect of the present invention is burner apparatus
comprising
[0019] (A) a central feed port having an axis;
[0020] (B) first supply apparatus for injecting a first stream
comprising material selected from the group consisting of fuel,
oxidant, and mixtures thereof, through the central feed port along
the axis of the central feed port;
[0021] (C) three or more outer ports, each having an axis which
converges or diverges with respect to the axis of the central feed
port; and
[0022] (D) three or more branched or unbranched supply lines, equal
in number to the number of outer ports, wherein one end of each of
said supply lines is connected to a different one of said supply
ports and the other end of each of said supply lines is connected
to a controllable supply apparatus for sequentially injecting
material selected from the group consisting of fuel, oxidant, inert
material, and mixtures thereof, into and through different ones of
said supply lines whereby said material is sequentially ejected
from different ones of said outer ports as a sequence of second
streams having a momentum sufficient to deflect the first stream
from the axis of said central feed port; [0023] wherein said
controllable supply apparatus comprises
[0024] (E) a valve that comprises a valve body having a valve
chamber therein having opposed first and second ends and a side
surface extending between said ends, the valve chamber including a
first region that extends from the first end of the valve chamber
and that has an axis, [0025] a valve distributor within the valve
chamber and rotatable therein in said first region about said axis,
the valve distributor having opposed first and second ends and a
side surface between said ends, that is positioned with its first
end facing the first end of the valve chamber and with its side
surface facing at least a portion of the first region of the valve
chamber, [0026] said valve chamber including an open space that is
bounded by the second end of said valve distributor, the second end
of the valve chamber, and the side surface of said valve chamber,
[0027] the valve body having an inlet extending therethrough from
the outer surface of said valve body to said open space, [0028] the
valve distributor containing a channel extending inwardly from the
side surface of the valve distributor and extending from the second
end of the valve distributor at least a portion of the distance
toward the first end of the valve distributor, to receive gas from
said open space, [0029] the valve body having two or more outlets
extending therethrough from the outer surface of said valve body to
points in the first region of the valve chamber that face the side
surface of the valve distributor or at least a portion of said
channel, [0030] wherein the outlets are dimensioned and located
with respect to each other so that at any rotational orientation of
the valve distributor the channel is open to one outlet or to more
than one outlet, and so that when the channel is open to more than
one outlet at the same time the sum of the interfacial areas at
said outlets stays within 90%, and preferably 50%, above or below
the maximum interfacial area when the channel is open to only one
outlet, and [0031] wherein the space between the side surface of
the valve distributor and the side surface of the valve chamber,
and the space between the first end of the valve distributor and
the first end of the valve chamber, are small enough that when gas
is fed into said inlet the amount that flows through said spaces to
an outlet that is not open to the channel is less than the amount
of gas that flows through the channel to the outlet or outlets to
which at least a portion of the channel is open, and
[0032] (F) a controller for turning said valve distributor about
its axis so that said channel is sequentially open to different
ones of said outlets so as to sequentially provide said material
from said open space through said channel to said outlets.
[0033] A preferred embodiment of the burner apparatus of the
present invention comprises
[0034] (A) a central feed port having an axis;
[0035] (B) three or more outer ports, each having an axis which
converges or diverges with respect to the axis of the central feed
port;
[0036] (C) one or more auxiliary feed ports situated closer to the
central feed port than any of said outer ports are;
[0037] (D) first supply apparatus for injecting a first stream
comprising material selected from the group consisting of fuel,
oxidant, and mixtures thereof, through the central feed port along
the axis of said central feed port;
[0038] (E) auxiliary stream supply apparatus for injecting an
auxiliary stream comprising material selected from the group
consisting of fuel, oxidant, and mixtures thereof, through said
auxiliary feed ports non-sequentially; provided that at least one
of said first stream and said auxiliary stream comprises fuel and
at least one of said first stream and said auxiliary stream
comprises oxidant, and
[0039] (F) three or more branched or unbranched supply lines, equal
in number to the number of outer ports, wherein one end of each of
said supply lines is connected to a different one of said supply
ports and the other end of each of said supply lines is connected
to a controllable supply apparatus for sequentially injecting
material selected from the group consisting of fuel, oxidant, inert
material, and mixtures thereof, into and through different ones of
said supply lines whereby said material is sequentially ejected
from different ones of said outer ports as a sequence of second
streams having a momentum sufficient to deflect the first stream
from the axis of said central feed port, [0040] wherein said
controllable supply apparatus comprises
[0041] (G) a valve that comprises a valve body having a valve
chamber therein having opposed first and second ends and a side
surface extending between said ends, the valve chamber including a
first region that extends from the first end of the valve chamber
and that has an axis, [0042] a valve distributor within the valve
chamber and rotatable therein in said first region about said axis,
the valve distributor having opposed first and second ends and a
side surface between said ends, that is positioned with its first
end facing the first end of the valve chamber and with its side
surface facing at least a portion of the first region of the valve
chamber, [0043] said valve chamber including an open space that is
bounded by the second end of said valve distributor, the second end
of the valve chamber, and the side surface of said valve chamber,
[0044] the valve body having an inlet extending therethrough from
the outer surface of said valve body to said open space, [0045] the
valve distributor containing a channel extending inwardly from the
side surface of the valve distributor and extending from the second
end of the valve distributor at least a portion of the distance
toward the first end of the valve distributor, to receive gas from
said open space, [0046] the valve body having two or more outlets
extending therethrough from the outer surface of said valve body to
points in the first region of the valve chamber that face the side
surface of the valve distributor or at least a portion of said
channel, [0047] wherein the outlets are dimensioned and located
with respect to each other so that at any rotational orientation of
the valve distributor the channel is open to one outlet or to more
than one outlet, and so that when the channel is open to more than
one outlet at the same time the sum of the interfacial areas at
said outlets stays within 90%, preferably 50%, above or below the
maximum interfacial area when the channel is open to only one
outlet, and [0048] wherein the space between the side surface of
the valve distributor and the side surface of the valve chamber,
and the space between the first end of the valve distributor and
the first end of the valve chamber, are small enough that when gas
is fed into said inlet the amount that flows through said spaces to
an outlet that is not open to the channel is less than the amount
of gas that flows through the channel to the outlet or outlets to
which at least a portion of the channel is open, and
[0049] (H) a controller for turning said valve distributor about
its axis so that said channel is sequentially open to different
ones of said outlets so as to sequentially provide said material
from said open space through said channel to said outlets.
[0050] Another aspect of the present invention is a combustion
method comprising
[0051] (A) injecting a first stream comprising material selected
from the group consisting of fuel, oxidant, and mixtures thereof,
through a central feed port that has an axis, along the axis of
said central feed port;
[0052] (B) providing three or more outer ports each having an axis
which converges or diverges with respect to the axis of the central
feed port;
[0053] (C) providing three or more branched or unbranched supply
lines, equal in number to the number of outer ports, wherein one
end of each of said supply lines is connected to a different one of
said supply ports and the other end of each of said supply lines is
connected to a controllable supply apparatus for sequentially
injecting material selected from the group consisting of fuel,
oxidant, inert material, and mixtures thereof, into and through
different ones of said supply lines,
[0054] (D) sequentially injecting said material into different ones
of said supply lines and thereby sequentially ejecting said
material through different ones of one or more of said outer ports
as a sequence of second streams having sufficient momentum to
deflect said injected first stream from the axis of said central
feed port and to form a mixture with the deflected first stream,
and
[0055] (E) combusting the mixture of first and second streams,
wherein said controllable supply apparatus comprises
[0056] (F) a valve that comprises a valve body having a valve
chamber therein having opposed first and second ends and a side
surface extending between said ends, the valve chamber including a
first region that extends from the first end of the valve chamber
and that has an axis, [0057] a valve distributor within the valve
chamber and rotatable therein in said first region about said axis,
the valve distributor having opposed first and second ends and a
side surface between said ends, that is positioned with its first
end facing the first end of the valve chamber and with its side
surface facing at least a portion of the first region of the valve
chamber, [0058] said valve chamber including an open space that is
bounded by the second end of said valve distributor, the second end
of the valve chamber, and the side surface of said valve chamber,
[0059] the valve body having an inlet extending therethrough from
the outer surface of said valve body to said open space, [0060] the
valve distributor containing a channel extending inwardly from the
side surface of the valve distributor and extending from the second
end of the valve distributor at least a portion of the distance
toward the first end of the valve distributor, to receive gas from
said open space, [0061] the valve body having two or more outlets
extending therethrough from the outer surface of said valve body to
points in the first region of the valve chamber that face the side
surface of the valve distributor or at least a portion of said
channel, [0062] wherein the outlets are dimensioned and located
with respect to each other so that at any rotational orientation of
the valve distributor the channel is open to one outlet or to more
than one outlet, and so that when the channel is open to more than
one outlet at the same time the sum of the interfacial areas at
said outlets stays within 90%, preferably 50%, above or below the
maximum interfacial area when the channel is open to only one
outlet, and [0063] wherein the space between the side surface of
the valve distributor and the side surface of the valve chamber,
and the space between the first end of the valve distributor and
the first end of the valve chamber, are small enough that when gas
is fed into said inlet the amount that flows through said spaces to
an outlet that is not open to the channel is less than the amount
of gas that flows through the channel to the outlet or outlets to
which at least a portion of the channel is open, and
[0064] (G) a controller for turning said valve distributor about
its axis so that said channel is sequentially open to different
ones of said outlets so as to sequentially provide said material
from said open space through said channel to said outlets.
[0065] A preferred embodiment of the method of the present
invention comprises
[0066] (A) injecting a first stream comprising material selected
from the group consisting of fuel, oxidant, and mixtures thereof,
through a central feed port that has an axis, along the axis of
said central feed port;
[0067] (B) providing three or more outer ports each having an axis
which converges or diverges with respect to the axis of the central
feed port;
[0068] (C) providing one or more auxiliary feed ports situated
closer to the central feed port than any of said outer ports
are;
[0069] (D) injecting an auxiliary stream comprising material
selected from the group consisting of fuel, oxidant, and mixtures
thereof, through said auxiliary feed ports non-sequentially;
provided that at least one of said first stream and said auxiliary
stream comprises fuel and at least one of said first stream and
said auxiliary stream comprises oxidant,
[0070] (E) providing three or more unbranched supply lines, equal
in number to the number of outer ports, wherein one end of each of
said supply lines is connected to a different one of said supply
ports and the other end of each of said supply lines is connected
to a controllable supply apparatus for sequentially injecting
material selected from the group consisting of fuel, oxidant, inert
material, and mixtures thereof, into and through different ones of
said supply lines,
[0071] (F) sequentially injecting said material into different ones
of said supply lines and thereby sequentially ejecting said
material through different ones of one or more of said outer ports
as a sequence of second streams having sufficient momentum to
deflect said injected first stream from the axis of said central
feed port and to form a mixture with the deflected first stream,
and
[0072] (G) combusting the mixture of first and second streams,
[0073] wherein said controllable supply apparatus comprises
[0074] (H) a valve that comprises a valve body having a valve
chamber therein having opposed first and second ends and a side
surface extending between said ends, the valve chamber including a
first region that extends from the first end of the valve chamber
and that has an axis, [0075] a valve distributor within the valve
chamber and rotatable therein in said first region about said axis,
the valve distributor having opposed first and second ends and a
side surface between said ends, that is positioned with its first
end facing the first end of the valve chamber and with its side
surface facing at least a portion of the first region of the valve
chamber, [0076] said valve chamber including an open space that is
bounded by the second end of said valve distributor, the second end
of the valve chamber, and the side surface of said valve chamber,
[0077] the valve body having an inlet extending therethrough from
the outer surface of said valve body to said open space, [0078] the
valve distributor containing a channel extending inwardly from the
side surface of the valve distributor and extending from the second
end of the valve distributor at least a portion of the distance
toward the first end of the valve distributor, to receive gas from
said open space, [0079] the valve body having two or more outlets
extending therethrough from the outer surface of said valve body to
points in the first region of the valve chamber that face the side
surface of the valve distributor or at least a portion of said
channel, [0080] wherein the outlets are dimensioned and located
with respect to each other so that at any rotational orientation of
the valve distributor the channel is open to one outlet or to more
than one outlet, and so that when the channel is open to more than
one outlet at the same time the sum of the interfacial areas at
said outlets stays within 90%, preferably 50%, above or below the
maximum interfacial area when the channel is open to only one
outlet, and [0081] wherein the space between the side surface of
the valve distributor and the side surface of the valve chamber,
and the space between the first end of the valve distributor and
the first end of the valve chamber, are small enough that when gas
is fed into said inlet the amount that flows through said spaces to
an outlet that is not open to the channel is less than the amount
of gas that flows through the channel to the outlet or outlets to
which at least a portion of the channel is open, and
[0082] (I) a controller for turning said valve distributor about
its axis so that said channel is sequentially open to different
ones of said outlets so as to sequentially provide said material
from said open space through said channel to said outlets.
[0083] Preferably, the first stream comprises material selected
from the group consisting of fuel, oxidant, and mixtures thereof,
and the second stream comprises material selected from the group
consisting of fuel, oxidant, inert material, and mixtures
thereof.
[0084] As used herein, the "axis" of a port is the centerline of
the path that fluid injected out of that port follows in the
absence of influence by intersecting fluid flows.
[0085] As used herein, material is "inert" if it does not
participate in the combustion of fuel and oxidant, and a stream of
material is "inert" if it does not contain material that
participates in the combustion of fuel and oxidant.
[0086] As used herein, the channel and an outlet are "open" one to
the other if gas can flow in a straight line through any part of
the opening of the outlet into any part of the channel, without
encountering solid structure.
[0087] As used herein, the "interfacial area" is the area of the
portion (up to 100%) of an outlet's opening in the inner side
surface of the valve chamber through which gas can flow radially
outwardly out of the channel in the valve distributor. For
instance, referring to FIGS. 11A and 11B (in which the outer
opening of the channel is narrower than the opening of the outlet)
and FIG. 11C (in which the outer opening of the channel is wider
than the opening of the outlet), the interfacial areas are the
areas of the shaded regions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0088] FIG. 1 is a front view of an embodiment of burner apparatus
according to one aspect of the present invention.
[0089] FIG. 2 is a cross-sectional view of the embodiment of FIG.
1, seen from above.
[0090] FIG. 3 is a cross-sectional view of the embodiment of FIG.
1, seen from the side.
[0091] FIG. 4 is a cross-sectional view of the embodiment of FIG.
1, seen from the side opposite the side from which FIG. 3 is
seen.
[0092] FIG. 5 is a front view of another embodiment of burner
apparatus according to the present invention.
[0093] FIG. 6 is a cross-sectional view of the embodiment of FIG.
5, seen from above.
[0094] FIG. 7 is a perspective view of the exterior of a valve
according to the present invention.
[0095] FIG. 8 is a cross-sectional view of a valve according to the
present invention.
[0096] FIG. 9 is a perspective view of a valve distributor useful
in the present invention.
[0097] FIGS. 10A and 10B are respectively top and side
cross-sectional views of another embodiment of a valve distributor
useful in the present invention.
[0098] FIGS. 11A, 11B and 11C are plan views of the opening of an
outlet seen from within a channel.
[0099] FIGS. 12A and 12B are plan views of representative
arrangements of openings of outlets that are adjacent to each
other.
DETAILED DESCRIPTION OF THE INVENTION
[0100] As indicated, one aspect of the present invention is the
combination of the valve described herein with a burner that can
generate a non-stationary flame.
[0101] The burner portion of the present invention is generally
referred to as 20 in FIGS. 1-4. Burner 20 is preferably formed of
refractory material that is capable of retaining its shape and
composition when exposed to the temperatures of 1000.degree. F. to
3000.degree. F. to which the burner may be exposed. Examples of
such materials include alumina, silica, AZS
(alumina-zirconia-silica), mullite, zirconia, and zirconite. Burner
20 can be part of a roof, side wall or bottom of an enclosure such
as a furnace in which the desired combustion is carried out.
[0102] Central feed port 9 and outer ports 1 through 8 open in the
front 22 of burner 20. Central feed port 9 and the outer ports may
be, but are not required to be, in the same plane, so long as the
other characteristics described herein are observed. Central feed
port 9 can comprise one opening as shown in FIG. 1, or can comprise
two or more openings (preferably 1 to 8, more preferably 1 to 3)
openings which should be located close to each other so that
material ejected out the openings merges in the form of a flow of
the ejected material having one axis 39 of flow. Examples include
multiple single holes, or concentrically arranged annular
openings.
[0103] While any number of outer ports greater than 2 outer ports
may be present, more than about 30 outer ports are usually not
necessary. Three to 20 outer ports are usually satisfactory, and
preferably 6 to 12 outer ports may be provided. The distance from
the central feed port 9 to each outer port can be the same, but
this is not necessary. Instead, each outer port that is provided
can be a different distance from central feed port 9, or some outer
ports can be one given distance from central feed port 9 while
another group of outer ports can be a second given distance from
port 9. That is, the outer ports can be arrayed in the form of one
circle around port 9, as shown in FIG. 1, or they may be arrayed in
the form of two circles of different diameters, or they may be
arrayed in the form of an ellipse, or two ellipses, or a rectangle,
or two rectangles, and so forth.
[0104] The surface that contains the ports can be planar (flat) or
concave or convex, preferably planar (flat) or concave. For concave
and convex cases, the surface on which the ports lie can be
spherical, ellipsoidal or a polyhedron shape.
[0105] Every outer port has an axis, and the axis of every outer
port converges or diverges with respect to the axis 39 of the
central feed port 9. As used herein, the axis of an outer port
"converges" with respect to the axis of the central feed port if
those two axes intersect downstream of front 22, and the axis of an
outer port "diverges" with respect to the axis of the central feed
port if those two axes intersect upstream of front 22, that is,
inside or behind burner 20. Preferably, the axes of all outer ports
all converge, or the axes of all outer ports all diverge, with
respect to the axis of the central feed port. More preferably, the
axes of all outer ports all converge with respect to the axis of
the central feed port.
[0106] The angle at which the axis of each outer port converges or
diverges with respect to the axis of the central fuel port is
typically 5 to 85 degrees and preferably 10 to 75 degrees. Outer
port axes that converge with respect to the central fuel port axis
can be parallel to each other, or converge toward each other, or
converge toward the same point on the central feed port axis. The
outer port axes do not necessarily have to converge toward the same
point: for instance, if the intent is to promote a moving flame
that moves half way on an elliptical contour and half way on a
circular contour, the axes of the outer ports would not converge
toward the same point on the central feed port axis.
[0107] Referring to FIGS. 2, 3 and 4, central feed port 9 is
connected by supply line 19 through burner 20 to first supply
apparatus, schematically represented as 40, which provides and
injects the material forming the first stream into supply line 19
so that it is ejected out through central feed port 9. Supply line
19 and central feed port 9 are aligned so that the first stream
ejected out of port 9 follows axis 39. Preferably, axis 39 of port
9 is perpendicular to surface 22.
[0108] Each outer port is connected by its own corresponding
separate supply line through burner 20 to supply apparatus,
schematically represented as 50, which provides and injects
material into each supply line so that the material is ejected as
second streams out of the outer ports in the manner described
herein.
[0109] Each supply line is branched or unbranched and connects
supply apparatus 50 at one of its ends to its own outer port at its
other end. Unbranched supply lines are preferred as they provide
the advantages of no diversion of material into branch lines or
through valves controlling access to branch lines. Using outer
ports fed by unbranched supply lines enables more reliable and
reproducible control of the flame pattern in the manner described
herein.
[0110] In FIGS. 2, 3 and 4, not all passages connecting to outer
ports are shown, for ease of reference and disclosure. As shown in
FIG. 2, outer ports 2 and 3 are fed by supply lines 12 and 13,
respectively, and outer ports 7 and 8 are fed by supply lines 17
and 18, respectively. Supply line 1 that feeds outer port 1 is not
shown in FIG. 2, so that supply line 19 can be shown, but supply
line 11 is shown in FIGS. 3 and 4. As shown in FIG. 3, outer ports
1 and 2 are fed by supply lines 11 and 12, respectively, and outer
ports 7 and 8 are fed by supply lines 17 and 18, respectively.
Supply line 13 feeding outer port 3 is not shown in FIG. 3 so that
supply line 19 can be shown. As shown in FIG. 4, outer ports 1 and
8 are fed by supply lines 11 and 18, respectively, and outer ports
6 and 5 are fed by supply lines 16 and 15, respectively. Supply
line 17 feeding outer port 7 is not shown in FIG. 4 so that supply
line 19 can be shown.
[0111] The supply lines feeding to the outer ports can proceed
straight through burner 20, as shown in FIGS. 1-4, but they can
instead be constructed to include a first portion, ending at the
outer port, whose axis is at a converging or diverging angle with
respect to the axis of the central feed port, and to include a
second portion intersecting with the first portion within burner 20
wherein the axis of the second portion is parallel to supply line
19 or is at some other angle with respect to the axis of the first
portion.
[0112] The supply lines feeding the outer ports are preferably
formed by drilling into the material from which the burner 20 is
fabricated. Preferably, the supply lines feeding the outer ports
and the supply line 19 feeding the central feed port are lined with
protective material such as metal. The supply lines can also be
created by casting a refractory block with large opening and
inserting removable nozzles.
[0113] In an alternate embodiment, at the opening of some or all
outer ports a nozzle or orifice can be provided through which the
stream is ejected. In such cases, the axis of the nozzle or orifice
is the axis of that outer port. The nozzles or orifices provided
for this use may be adjustable so that the axis of each nozzle or
orifice can be moved without having to replace or redrill the
supply line that feeds to the outer port.
[0114] The material ejected as the first stream and the material
ejected as the second stream must, after they have been mixed
together, be capable of combusting in the presence of an external
or embodied source of ignition or in a combustion chamber at
temperatures higher than the self ignition temperature of fuel
present in the mixture.
[0115] In one embodiment, the material ejected as the first stream
and the material ejected as the second stream both comprise
material which participates in combustion of the mixture that is
formed of the first and second streams. For instance, the first
stream can comprise fuel, in which case the second stream comprises
oxidant or a premixed mixture of fuel and oxidant. Instead, the
first stream can comprise oxidant, in which case the second stream
comprises fuel or a premixed mixture of fuel and oxidant. In
another alternative, both of the first stream and the second stream
comprise premixed mixtures of fuel and oxidant. Preferably, the
first stream comprises fuel and the second stream comprises
oxidant.
[0116] In another embodiment, the material ejected as the first
stream comprises fuel or a mixture of fuel and oxidant, and the
second stream is "inert", that is, it does not contain material
which participates in combustion of the mixture that is formed of
the first and second streams. Examples of such material that could
be ejected as the second stream include nitrogen, argon, carbon
dioxide, water (liquid or, preferably, vapor), helium, and mixtures
thereof.
[0117] Suitable fuels include combustible hydrocarbons whether
gaseous, liquid, or particulate solid in form. Suitable gaseous
fuels include natural gas, vaporized LPG (liquefied petroleum gas),
propane, butane, and gaseous mixtures that contain carbon monoxide,
hydrogen, or both carbon monoxide and hydrogen, such as coke oven
gas, blast furnace gas, electric arc furnace gas, and coal gas.
Suitable liquid fuels include fuel oil and diesel oil. Liquid fuel
should be atomized as it emerges from its port (whether the central
feed port or outer ports). Suitable solid fuels include coal of any
rank or mixtures of rank, and petroleum coke. When the fuel is
solid, it should have been reduced in particle size so that it is
capable of being fed out of the port with a suitable carrier gas
such as transport air, as is used when feeding pulverized coal to
the combustion chamber of a coal-fired electricity generating power
plant.
[0118] The oxidant should be a stream that contains 5 vol. % to 100
vol. % oxygen, and preferably 10 vol. % to 100 vol. % oxygen. Air
is a preferred oxidant, as is oxygen-enriched air by which is meant
air to which oxygen has been added to raise the oxygen content
above that of air to e.g. at least 20 vol. % or 25 vol. % or even
at least 50 vol. %. Another preferred oxidant is a gaseous stream
containing at least 80 vol. % oxygen or even at least 95 vol. % or
even at least 98 vol. % oxygen. Oxidant having this higher oxygen
content can be provided from storage tanks that contain compressed
oxygen gas, from storage tanks that contain liquid oxygen and
provide the oxygen by vaporization of suitable amounts of the
liquid oxygen, or from on-site air separation units that produce
high-purity oxygen from air, or from an oxygen pipeline. Other
gaseous components (such as the aforementioned materials that do
not participate in combustion) can likewise be provided from
storage tanks, supply trucks, or pipelines
[0119] The supply apparatus 40 that injects into supply line 19 the
material that is ejected from port 9 as the first stream, and the
supply apparatus 50 that injects into the supply lines the material
that is ejected from the outer ports as the second streams, include
a suitable source of fuel, or oxidant, or premixed fuel and
oxidant, or non-combusting material, as the case may be, as well as
suitable apparatus for propelling the material to and through its
port(s). Suitable devices for gaseous material include fans and
blowers. Suitable devices for liquids and particulate solids
include atomizers and blowers having the ability to perform the
necessary function of delivering the material to and through the
port(s) with the desired velocity. The additional capabilities of
supply apparatus 50 are described below.
[0120] The velocity of the first stream ejected by the central feed
port should typically be 5 to 1600 feet per second, and preferably
10 to 900 feet per second. The velocity of the second stream
ejected by each outer ports should typically be 5 to 2000 feet per
second and preferably 10 to 900 feet per second.
[0121] The temperature of the mixture of the first and second
streams should typically be up to 3000.degree. F., and preferably
up to 2000.degree. F.
[0122] In accordance with the present invention, in sequence (1) a
second stream is ejected from one outer port, or from a group of
adjacently located outer ports, with sufficient momentum to deflect
the ejected first stream from the axis along which it would
otherwise be traveling in the absence of that deflection, while at
that same point in time material is either not being ejected from
other outer ports, or is being ejected from other outer ports but
not with enough momentum to deflect the first stream from its axis,
and then (2) a second stream is ejected from a different outer
port, or from a different group of adjacently located outer ports,
with sufficient momentum to deflect the first stream (in a
direction different from the direction it was previously deflected)
from the axis along which it would otherwise be traveling in the
absence of that deflection, while at that same point in time
material is either not being ejected from other outer ports, or is
being ejected from other outer ports but not with enough momentum
to deflect the first stream from its axis, following which the
ejection of second streams continues from a periodically changing
outer port or group of outer ports. It should be noted that the
flow of second streams of material that deflect the flow from the
central feed port can occasionally be reduced, or interrupted, so
that the ejected first stream of material flows along the axis of
the central feed port temporarily, following which a second stream
is again ejected from an outer port or group of outer ports to
again deflect the first stream.
[0123] To carry out this function, supply apparatus 50 that injects
material into the supply lines for ejection from the respective
outer ports as the second streams includes mechanism for
sequentially varying the supply line or lines into which the
material is injected, with a high enough velocity, to sequentially
vary the outer port or ports through which the second stream is
ejected at any point in time with a momentum high enough to deflect
the first stream being ejected from the central feed port from its
axis.
[0124] The preferred mode of sequentially controlling the flow of
material comprising the second stream through the outer ports
employs a single-valve mechanism, situated between the individual
supply lines and an upstream common source of supply of the second
stream material, that includes a movable piece such as a rotatable
diverter. The movable piece contains a principal opening through
which the second stream material can flow into an outer port supply
line with which the principal opening is aligned at any particular
point in time. The movable piece otherwise blocks flow to the other
outer port supply lines, or optionally also includes additional
openings which are aligned with one or more of the other outer port
supply lines when the principal opening is aligned with one of the
outer port supply lines. The movable piece and the outer port
supply lines are positioned with respect to each other so that the
movable piece can be moved (for instance, rotated around its own
axis) so as to bring outer port supply lines into alignment with
the principal opening in a sequence that enables the material
comprising the second stream to flow to a sequence of outer ports.
When the material comprising the second stream is applied under
pressure upstream of the movable piece, rotation of the movable
piece aligns the principal opening with a sequence of outer port
supply lines while permitting the second stream to flow into no
other outer port supply lines, or in lesser quantities into other
outer port supply lines, depending on whether any of the aforesaid
additional openings are provided.
[0125] Preferred embodiments of this mechanism are described
herein, with reference to FIGS. 7, 8, 9, 10A, 10B, 11A, 11B and
11C.
[0126] Referring to FIG. 7, valve 50 includes valve body 48 which
has an outer surface 51 through which pass inlet 55; outlets 56,
and optional but preferred seal leakage vents 57. Bottom plate 58,
top bearing seal 62 and first spindle 60 are also shown. The first
spindle 60 can include flat region 87 to facilitate attaching
apparatus (a motor, or gears which are attached to a motor) which
controllably rotates the spindle and the valve distributor 82. The
valve body 48 is preferably made of metal such as steel or
brass.
[0127] FIG. 8 shows the interior of the valve, including inlet 55,
two outlets 56, bottom plate 58, top bearing seal 62, and first
spindle 60, which appear in FIG. 7. Valve body 48 houses valve
chamber 49 which has first end 52, second end 53, and wall surface
54. Surface 54 is shown as being cylindrical for at least the
portion of the chamber 49 within which valve distributor 82
rotates. However, this portion of surface 54 can instead have a
different shape, such as conical (converging upwardly toward a
point or diverging upwardly), or other shape within which the valve
distributor can rotate. Also shown in FIG. 8 are second spindle 61,
one countersunk screw 64 of several that would hold bottom plate 58
to valve body 48, access plug 66 for accessing and replacing bottom
bearing 70, access plug o-ring seal 67 and its groove 68, bottom
bearing 70, bottom plate o-ring seal 71 and its groove 72, top
o-ring seal 73 and its groove 74, seal leakage deflection collar
76, seal leakage expansion chamber 78 (which connects by ducts, not
shown, to vents 57); top bearings 79 (preferably an angular contact
rolling element pair for thrust and radial loads), and bearing
retaining clip 80. Valve distributor 82 has first end 83, second
end 84, and outer surface 85. Space 86, not fully occupied by valve
distributor 82, is within valve chamber 49 in the region into which
inlet 55 feeds gas. Second spindle 61 is optional but preferred, to
provide stability for the rotating valve distributor.
[0128] FIG. 9 shows valve distributor 82, first spindle 60, second
spindle 61, and first end 83, flat region 87, groove 88 for
retaining clip 80, and seal leakage deflection collar 76. Valve
distributor 82 is shown as being cylindrical in shape but it can
instead have another shape such as conical (converging upwardly
toward a point or diverging upwardly) which corresponds closely to
the space closer to the first end 52 of valve chamber 49. Also
shown is channel 90, which is open at outer surface 85 of valve
distributor 82 and extends inwardly into valve distributor 82.
Channel 90 is open at second end 84 and extends upwardly from
second end 84 at least partway toward first end 83, far enough so
that it can be open to the outlets 56 as valve distributor 82
rotates. Channel 90 is shown as extending upwardly from end 84 in a
direction parallel to the axis of rotation. Channel 90 can instead
have a different path, such as helical, along surface 85.
[0129] Valve distributor 82 fits closely within valve chamber 49
but space can be provided between the side wall surfaces 85 and 54
of valve distributor 82 and valve chamber 49, and between the first
ends 83 and 52 of valve distributor 82 and valve chamber 49, so
that a minor amount of gas can flow from space 86 through that
space to reach every outlet, even outlets that are not at the
moment open to the channel 90. Providing some gas to each outlet at
all times is preferred as it provides some cooling to the openings
at the front of the burner.
[0130] As indicated above, the space between the side surface 85 of
valve distributor 82 and the side surface 54 of valve chamber 49,
and the space between the first end 83 of valve distributor 82 and
the first end 52 of valve chamber 49, are small enough that when
gas is fed into said inlet the amount that flows through said
spaces to an outlet that is not open to the channel 90 is less than
the amount of gas that flows through the channel 90 to the outlet
or outlets to which at least a portion of the channel 90 is open.
Preferably, the spaces are small enough that even less gas can pass
therethrough, that is, the amount that flows through said spaces to
an outlet that is not open to the channel 90 is not more than 25%,
more preferably not more than 10%, and even more preferably not
more than 5%, of the amount of gas that flows through the channel
90 to the outlet or outlets to which at least a portion of the
channel 90 is open
[0131] FIGS. 10A and 10B illustrate another, optional, manner in
which gas can be provided to outlets. Passageway 92 is provided
through valve distributor 82, from an opening 91 in channel 90
(whether in the bottom of channel 90, as shown in FIG. 10A, or in
one of the walls of channel 90, as shown in FIG. 10B) to an opening
93 in the side surface of valve distributor 82. In a preferred
version of this embodiment, adjustable screw 94 is provided whose
tip extends to or into passageway 92. By turning the screw to
adjust how much of the tip extends into passageway 92, or to move
the tip out of passageway 92, one can vary the amount of gas that
flows through and out of passageway 92. In the embodiment of the
valve illustrated in FIGS. 7 and 8, the adjustment screw 94 could
be accessed by removing bottom plate 58.
[0132] The outlets 56 can be arrayed in any of a number of ways
around the valve body 48, but certain arrangements are preferred.
The outlets are preferably placed on two or more levels, to allow
closer packing of the outlets so that a smaller valve may be used
(for ease of manufacture, handling and economy). The limit of the
port packing tightness is based on at least two constraints. The
first is in good practice for the attachment of conduits to the
outlet conduits, so that the fastening of any one of the outlet
conduits will not interfere with the fastening of the other outlet
conduits. This applies to threaded connections where either the
high points of the hose end connecting adapter would interfere or
where turning of the wrench itself would be overly obstructed. It
also applies in cases where other means of attachment are used such
as welding or quick-disconnects. Another consideration in the
tightness of the packing of the outlets is in the allowable
stresses of the material remaining between the ports given the
internal pressure, any bending moments induced by the weight of
attached hoses, and induced stress from the method of attachment
whether it be threaded, welded, flanged or quick disconnects.
[0133] Another preferred mode is that the outlets are sized
identically and distributed evenly. It should be noted that while
relatively constant flow through the various outlets may be desired
in some applications of this invention, it is not required in
others. Thus, the descriptions herein of how to make a valve
according to this invention need not be limited to embodiments that
provide such relatively constant flows.
[0134] In addition, a preferred distribution of the outlet ports is
such that a single line drawn vertically tangent with the interior
edge of one of the outlets either does not intersect the adjacent
outlet, or is a tangent line for the interior edge of the adjacent
outlet. This relationship is illustrated in FIG. 12A. For instance,
for a six port valve in this mode of arranging the outlets, there
are six evenly spaced, imaginary, vertical lines each of which is
simultaneously tangent to two adjacent outlets. At the same time,
channel 90 is sized so that at the surface 85 of valve distributor
82 it is the same nominal width as the diameters of the outlets at
the wall surface 54. This arrangement enables maintaining a
constant primary outlet flow area no matter the position of channel
90. That is, as valve distributor 82 rotates and the interfacial
area with one outlet decreases, the edge of the adjacent outlet
port begins to be open and the interfacial area with that next
outlet increases by a corresponding amount so that the same total
outlet area is exposed to the flowing gas.
[0135] The outlets can instead be spaced more closely, so that a
vertical line on surface 54 can pass through two or more outlets.
However, it is still preferred that even if the outlets are spaced
so that a vertical line that is tangent to one outlet opening can
pass through the opening of the closest adjacent outlet, the
outlets should still be spaced apart from one another enough so
that a vertical diameter of one outlet's opening does not intersect
the opening of any of the closest adjacent outlets. This
relationship is illustrated in FIG. 12B.
[0136] The spacing of the outlets achieves the aforementioned
preference that at any rotational orientation of the valve
distributor the channel is open to one outlet or to more than one
outlet, and that when the channel is open to more than one outlet
at the same time the sum of the interfacial areas at said outlets
stays within 90% above or below the maximum interfacial area when
the channel is open to only one outlet. Preferably, the sum of the
interfacial areas at said outlets stays within 50% or 25%, more
preferably within 10%, and even more preferably within 5%, above or
below the maximum interfacial area when the channel is open to only
one outlet.
[0137] Sizing of the valve is based upon the amount of flow
required through the connections and the number of connections
needed. Generally the connections are sized to keep the pressure
drop reasonable and economical and this is done with a flow
velocity less than sonic velocity and generally between 10 and 300
ft/s. The size of the valve body is then based upon the diameter
and height required to distribute the number and size of
connections around the periphery while maintaining a suitably
sturdy device (by not allowing the distance between openings to be
so narrow that the material cannot carry the loads required) and
considering that the valve distributor must be able to transition
from outlet to outlet without significantly altering the flow. The
channel 90 itself is sized to maintain the velocity less than sonic
velocity and generally between 10 and 600 ft/s for a reasonable and
economical pressure drop. Materials of construction are selected
based on whether materials will be in contact with the process
fluid.
[0138] In operation, gas (preferably, the oxidant rather than fuel,
though it can ge gaseous fuel) is fed into inlet 55 from a source
(not shown) such as a pump or a tank in which the gas is stored
under pressure. The source should have controls such as an
adjustable valve that enables the flow of gas to be shut off,
turned on, and varied in flow rate. The gas enters into space 86
and passes into channel 90 and then to various outlets 56 as the
valve distributor 82 rotates under the action of a motor that can
be controlled so that the operator can vary or set the rate at
which the valve distributor is rotated, and preferably the length
of time that the valve distributor rests in each position it takes
that aligns channel 90 with one or more outlets. The controller
preferably also controls the sequence of outlets at which the
channel 90 is aligned.
[0139] The valve described herein can be electronically or
pneumatically controlled. With electronic control, a variable
frequency driver would drive an electric motor which turns the
rotary valve, and the rotational speed would be controlled by a
PLC. Alternatively, the valve can be rotated by a stepper motor
that is executing a program stored in a motor control unit. To
control a pneumatically operated rotary valve, the supply pressure
of the compressed driving fluid would be varied and controlled.
[0140] Using either of these control schemes or any other control
scheme that achieves the same function, the second stream is
provided in sequence through an outer port or to a group of
adjacent outer ports at a momentum sufficient to deflect the first
stream from its axis. The sequential feeding of second streams
having that momentum sequentially changes the outer port or outer
ports which is or are ejecting the second streams that deflects the
first stream, which in turn sequentially changes the direction in
which the first stream is deflected. The sequence of first
stream-deflecting flows of second streams preferably proceeds
around and around the array of outer ports, from one outer port and
then from its nearest neighbor and then from that outer port's
nearest neighbor and so forth, such as out of outer ports 1 through
8 in the numerical sequence in which they are numbered in FIG. 1,
with flow out of outer port 8 being followed by flow out of outer
port 1, and so on. Alternatively, the sequence of outer ports from
which first stream-deflecting flows of second streams are ejected
can skip from one outer port to another non-adjacent outer port,
then to another that is adjacent or non-adjacent, and so forth.
Furthermore, the sequence can be repetitive, or it can be
randomized so that there is no regularity to which outer port will
be the next to eject a second stream to deflect the flow of the
first stream. The sequence, whether regular or randomized, can be
programmed into and carried out by the PLC.
[0141] Typically, the direction of flow of the first
stream-deflecting flow of the second stream changes often enough
that a complete sequence of direction changes occurs in 0.03 to 30
minutes, preferably 0.1 to 10 minutes.
[0142] While the present invention can be carried out by ejecting
first stream-deflecting flows of material as the second stream from
one outer port at a time, it is also possible and often is
preferred to eject the second streams from a pair of adjacent outer
ports at a time, or from a group of three outer ports comprising a
middle port and an adjacent port on each side of the middle port.
That is, referring to FIG. 1, the second stream that deflects the
first stream can come from any one of outer ports 1 through 8, or
from two adjacent ports at a time such as from ports 1 and 2, then
from ports 2 and 3, then from ports 3 and 4, and so forth.
Alternatively, the flows can come from ports 1, 2 and 3, then from
ports 2, 3 and 4, then from ports 3, 4 and 5, and so forth. Indeed,
the number of outer ports from which a second stream is directed to
deflect the first stream can be from only 1 up to 1 less than the
total number of outer ports, and preferably from 1 to 4 outer
ports.
[0143] The ratio of the momentum of the stream ejected by the outer
port or outer ports which deflect the first stream, to the momentum
of the first stream from the central feed port, is typically 1.01
to 20 and preferably 1.1 to 10.
[0144] The exit openings of the ports can vary in shape (geometry)
and area as long as the streams are ejected within an effective
velocity range (which for the first stream ejected from the central
feed port is a velocity typically between 5 to 1600 feet per
second, and preferably 10 to 900 feet per second; and for the
second stream ejected by outer ports is a velocity between 5 to
2000 feet per second, and preferably 10 to 900 feet per
second).
[0145] The distance between the outer port to the center port can
vary from outer port to outer port. Preferably, the outer ports
should lie on a circular or elliptical pattern.
[0146] Of the total amount of material ejected as second stream
through all outer ports at any point in time, typically 10 to 100%
and preferably 50 to 100% of that amount should be ejected by the
outer port or ports that are providing the momentum to deflect the
first stream.
[0147] When the axes of the outer ports converge with respect to
the axis of the central feed port, the first stream-deflecting
second stream or streams deflects the first stream from its axis by
"pushing" it from its axis. When the axes of the outer ports
diverge with respect to the axis of the central feed port, the
first stream-deflecting second stream or streams deflects the first
stream from its axis by drawing or aspirating the first stream
toward the second stream(s). In either situation, the second stream
or streams intersects with and mixes with the first stream.
[0148] Once ignited, the mixture that forms of the first and second
streams combusts and forms a flame. The direction in which the
first stream is deflected (by the second stream or streams) becomes
the direction in which the mixture of the first and second streams
extends which in turn is the direction that the flame extends.
Thus, the orientation of the flame with respect to the axis of the
central feed port changes with each intersection between the first
stream and a first stream-deflecting second stream coming from a
different outer port or group of outer ports. For example, carrying
out the present invention with a burner like that shown in FIGS.
1-4, and ejecting the second stream from the outer ports in the
numerical sequence of ports 1 through 8 in that order, then as one
looks at the front of the burner in the view provided in FIG. 1 the
flame would be deflected so that the flame would obscure port 5,
then port 6, then port 7, then port 8 (at which point the first
stream-deflecting flow of second stream would be from port 4) and
so forth as the flame would continue to appear to sweep out a cone
whose vertex would be at port 9.
[0149] This behavior continually provides the desired heat of
combustion to the material being heated and to the enclosure in
which the combustion is occurring, but does so in a way that
provides a more uniform temperature distribution because the
continually shifting orientation of the flame avoids the creation
of "hot spots" or regions which become overheated because of the
uninterrupted proximity to the hottest regions of the flame. This
in turn permits combustion conditions that provide a hotter average
flame temperature, since there is less need to be constrained by
avoidance of "hot spots".
[0150] The ratio (or proportion) of material in the first and
second streams needs to be appropriate to maintaining combustion of
the mixture that forms upon intersection and mixing of the first
and second streams. Thus, for each mixture of fuel and oxidant that
forms as the flame changes orientation by ejection of second stream
from each sequentially differing outer port, taking into account
oxidant entering the flame from the surroundings plus any oxidant
fed through any auxiliary feed port(s) plus oxidant fed in the
first and second streams, the ratio of the total amount of oxygen
fed to the amount of fuel fed must be from 0.5 to 10 times the
stoichiometric ratio, where the stoichiometric ratio is defined as
the mole amount of oxygen per mole of fuel that is required to
completely combust the fuel to CO.sub.2 and H.sub.2O. For instance,
the stoichiometric ratio defined in this way for combustion of
methane is 2, so the ratio of oxygen to methane to establish in
each mixture of first and second combustant that is formed is
2.times.(0.5 to 10) or 1 to 20.
[0151] The distance between the axis of the central feed port and
the nearest outer port is typically 3 to 24 inches and preferably 6
to 18 inches.
[0152] In addition to providing the advantage of a more uniform
temperature profile of the surface of the material to be heated, or
heated and melted, and for the resulting heating that the flame
provides, the present invention is advantageous in that it can be
carried out using staged combustion techniques that help reduce
production of nitrogen oxides. Staging can be effected by
permitting the injection of small amounts of material through the
outer ports that are not involved at a given point of time in
deflecting the first stream.
[0153] A preferred alternative embodiment, illustrated in FIGS. 5
and 6, includes one or more auxiliary feed ports through which a
stream is ejected to help stabilize the flame and control formation
of nitrogen oxides. A preferred auxiliary feed port is an annular
orifice 60 around the central feed port 9. Instead, the annular
orifice 60 can be replaced by a series of distinct openings arrayed
around the central feed port 9. The one or more auxiliary feed
ports are closer to the central feed port than any of the outer
ports are. The auxiliary feed port or ports are fed through
auxiliary supply line 58 from auxiliary feed source 56. In this
embodiment, the stream ejected by the central feed port 9 comprises
fuel, oxidant, or a mixture of fuel and oxidant, and the auxiliary
feed port or ports 60 eject fuel, oxidant, or a mixture of fuel and
oxidant, provided that at least one of the central feed port and
the auxiliary feed port(s) ejects fuel and at least one of the
central feed port and the auxiliary port(s) ejects oxidant. The
material fed to the central feed port and the material fed to the
auxiliary port(s) by their respective sources of supply 40 and 56
are provided and injected by means of apparatus known in this
technical field.
[0154] The material fed to auxiliary feed port or ports 60 is fed
non-sequentially, that is, the rate at which material is fed to and
through the auxiliary feed port(s) does not vary during operation,
and does not fluctuate between different rates during
operation.
[0155] The invention provides many other advantages. One is that
the present invention provides a flame with wide coverage to
transfer heat more efficiently to the material being heated. Also,
flame direction can be changed easily, even during operation of the
burner, without requiring any change to the hardware (burner and/or
flow control valves), simply by changing the directions to the
controller that governs the sequential feeding through the outer
ports.
[0156] Another advantage is the ability to point the flame in a
pre-determined direction for a pre-determined period of time. That
is, the flame does not need to be moving constantly. The frequency
of the changes of flame orientation, and the period of time the
flame points in any given direction can be set, for instance, at
the moment the furnace is charged and according to the way the
furnace has been charged (for instance, the flame can stay pointed
to a given direction where there is a greater amount of charged
material to be heated, or where there is more freshly charged
material that is initially at a lower temperature.
[0157] Additional benefits of the invention include:
[0158] Fewer "hot spots" are formed in the refractory wall, which
can increase the furnace life.
[0159] Promoting more uniform heat transfer pattern means fewer
"cold spots", which can lead to increased melt rate or heat
rate.
[0160] Fewer burners are required due to the uniform heat transfer
pattern, thus affording equivalent production for a lower
investment.
[0161] A burner installed in the roof leaves more locations in the
side wall to install peep holes, service doors, and charging
doors.
[0162] A burner with moving flame installed in the roof allows the
design of the combustion system to be optimized for the furnace
geometry.
[0163] The direction of the flame and the intensity of the flame
are determined by independent jets, i.e., do not rely on nozzle
design, gas mixing, fluid flow pattern, and material reliability
against degradation factors such as chemical attack or spalling,
and is less sensitive to variations in operating parameters that
would affect flame stability. The flame stability and
characteristics are determined by fixed and robust gas injection
ports. The greater uniformity of temperature avoids localized high
temperature regions or spots since the heat is transferred evenly
around the burner (or melting or heating surface) and not only on
one stripe across the charge. The heat is evenly and gently
distributed over the charge. This also permits a potentially lower
oxidation rate when heating materials susceptible to oxidation due
to localized high temperature and high oxygen partial pressure,
such as aluminum and steel.
[0164] Other advantages include high flame stability and reduced
downtime, because in the unlikely event of clogging of an outer
port, the sequence of injection can be revised to avoid using that
port until suitable repairs can be made.
[0165] The invention also provides economic advantages including
low fabrication cost, yield improvement in applications where
oxidation is a concern, such as aluminum melting and steel
reheating, and low specific fuel consumption.
* * * * *